Spectra Watermakers CATALINA 300 MPC-5000 Operating instructions

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Spectra Watermakers, Inc.
20 Mariposa Road, San Rafael, CA 94901
Phone [phone] Fax [phone]
E-mail: [email protected]
www.spectrawatermakers.com
20 Feb,2006 MPC-5000
CATALINA 300 MPC-5000
INSTALLATION & OWNER’S
MANUAL
Part 1……....Installation, Operation, Maintenance
Part 2………………….. Programming and Controls

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Catalina Installation Quick Start
Important Details for Installer
The system must have a dedicated sea water inlet to guarantee a solid flow of water to
the system. The inlet should be as low in the boat as possible and with a scoop type for-
ward facing thru-hull fitting installed.
Follow the wire gauge charts in the instructions. Using larger wire than specified is ac-
ceptable.
The MPC control must have continuous DC power to achieve the full benefits of the
fresh water flush system. The domestic fresh water pressure must be on and the fresh
water tank level maintained. Calculate 3 gallons (12L) per flush..
The MPC 5000 control must be de-powered (DC power off) after the system is put in
storage and “pickled”, when a storage chemical or antifreeze is run through the system.
If you are separating the Clark Pump/membrane assembly, please review the high pres-
sure tube assembly instructions. Improper assembly will cause failure!
Run test, then “sea trial” the complete system before assuming the system is opera-
tional. If the boat is in fresh or dirty water, see “Dry Testing the System.”
Spectra dealers are responsible for educating the vessel owners on the operation and
maintenance of the system. We request that you “walk through” the installation with
our customer.
Please have the owner fill out the warranty card. The warranty is void if it is not regis-
tered.
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Thank you for your purchase of a Spectra Catalina system. Properly installed, it will provide
years of trouble-free service. Please pay attention to the installation instructions and the sys-
tem layout. Like any piece of mechanical equipment, the system will require inspection and
service from time to time. Do not place the components in inaccessible areas that will pre-
vent proper maintenance. If you are having a dealer install the system for you, review the
location of the components to make sure that the installation will meet your approval upon
completion.
Both the Catalina Mag Drive feed pump module and the Clark Pump/membrane mod-
ule must be installed in a well-ventilated compartment where temperatures will not
exceed 120oF (48oC). Many engine compartments exceed this temperature when un-
derway. Warranty will be void if the installation does not meet this requirement.
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Table of Contents
Installation
Operation
Getting Started .....................................................................................................................7
Catalina Schematic ..............................................................................................................8
Installation Basics ................................................................................................................9
Component Placement .......................................................................................................10
Plumbing............................................................................................................................13
Parker Tube Fitting Assembly Procedure..........................................................................16
Membrane Pressure Vessel Relocation..............................................................................17
Wiring ................................................................................................................................19
MPC Tank Switch Wiring and operation……………………………………………….. 25
Wiring Diagram .................................................................................................................26
Z Brane Installation ...........................................................................................................53
Page Number
New Systems Start Up and Testing ...................................................................................27
Dry Testing ........................................................................................................................30
Normal Start Up Using the Auto Run................................................................................31
Automatic Fresh Water Flush Cycle..................................................................................32
Manual Operation ..............................................................................................................33
Maintenance.......................................................................................................................38
Bulletins…………………………………………………………………………………..45
Service & Maintenance
Long Term Storage Procedures .........................................................................................34
Winterizing ........................................................................................................................37
Membrane Cleaning...........................................................................................................39
Salinity Probe Calibration..................................................................................................41
Suggested Spares ...............................................................................................................42
Catalina Troubleshooting Procedures, Service Bulletins...................................................43
Parts breakdown for all Catalina Magdrive systems .........................................................56

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Unpack the system and inspect it to make sure that it has not been damaged in shipment.
Refer to the shipping list for your system to make sure you have received all of the compo-
nents listed. Do not discard any packaging until you have found and identified all of the
parts. The small installation parts are listed on the cellophane bags’ pick list.
We will not be held responsible for shortages and/or freight damage that are not reported
within thirty days of the ship date.
Next, study the system layout diagram, component photos, and descriptions before begin-
ning your installation. This will assist you in understanding the function of each component.
Layout the system. Before starting the installation, identify the location where each module
and component will be placed. Insure that there is proper clearance around the components
for removal of filters and system service. Also check to make sure you have adequate tubing
and hose before starting so additional parts may be ordered. Check to see that the MPC cable
is long enough to reach from the display location to the main module.
Catalina Mag Drive shipping list:
•Catalina MPC Magnetic Drive Feed Pump Module
•High Pressure Clark Pump and Reverse Osmosis Membrane Module
•Fresh Water Flush Module
•Dual Filter Assembly
•Catalina Installation Kit
•Accumulator / Gauge Assembly
•Service Hose Kit
•5/8” Hose (25’)
•3/4” Suction Hose (25’)
Getting Started

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Three feet (1.2M)
CATALINA 300 MPC
SCHEMATIC

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Installation Basics
•Read the directions!
•Avoid tight hose bends and excessive runs.
•Use heavy gauge wire.
•Install feed pump as low as possible.
•Use a dedicated thru-hull with scoop-type strainer.
Thru-hulls
It is mandatory that a dedicated 3/4” to 1” forward facing scoop-type intake thru-hull and sea-
cock be installed. Install the intake for the system close to the middle and as far below the
water line as possible. Thru-hulls in the bow area are susceptible to air intake in rough condi-
tions. Sharing a thru-hull with another system is not acceptable and will void the warranty.
Sharing a thru-hull can introduce unforeseen problems such as intermittent flow restriction,
air bubbles, and contaminates. For racing boats and high speed power boats above 15 knots a
retractable snorkel-type thru-hull fitting is preferred to be able to pick up water away from
the hull.
Do not install the intake close to or downstream of a head discharge. Install as far below the
waterline and as close to center line as possible to avoid contamination and air induction.
The brine discharge thru-hull should be mounted above the waterline, in or just above the
boot stripe to minimize water lift.
Double clamp all hose connections below the waterline.
Pipe Fitting Instruction
Plastic-to-plastic fittings should have 3 to 4 wraps of Teflon tape and will thread almost all
the way in.
Avoid getting dirt or debris into the piping or hoses during assembly. A small bit of de-
bris can stop the system! Avoid getting tape over the end of fittings that might get into the
system. To insure this does not happen, leave the very first thread uncoated.
Avoid restrictions or long runs on the entire inlet side of the plumbing from the thru-hull to
the main feed pump module.
Prevent tight bends and excessive elbows. Any restrictions will hamper system performance.
Secure the piping away from moving objects such as engine belts and hatches. Prevent chafe
on the tubing as required. Test and inspect all piping and hose clamps after several hours of
operation.
Flow
Wiring
•Pay attention to wire size or system performance will be impaired.
•Perform wiring to UL, ABYC, CE or applicable standards.
Thru-hull
not supplied.

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Component Placement
Refer to the Plumbing Diagrams
Strainer
Mount the strainer in an accessible area close to the intake thru-hull
that can handle water spillage during service. Extra care during as-
sembly must be taken to avoid air leaks from the strainer. Use the
supplied “quick block” and wire tie for mounting.
The fresh water flush module should be located between the intake
strainer and the feed pump module and as low as possible in the
vessel. It should be mounted with the filter housings vertical and
accessible for changing filters. Allow 2” below the filter housing
for removal. Do not install over electrical equipment. Remove filter
bowls for access to the screw holes in the mounting plate. The unit
contains a 50 micron prefilter, charcoal filter for the flush water,
flush solenoid and three way intake service valve.
Optional Z– Brane
The optional Z-Brane water treatment system is permanently in-
stalled in the membrane pressure vessels and continuously helps
prevent biogrowth and fouling of the membrane system.
Feed Pump/Main Module
Fresh Water Flush Module
Mount the feed pump/main module on a horizontal or vertical sur-
face that can be up to 3’ (1.0 M) above the waterline. It is prefer-
able to mount as low as possible. Choose a location which will
allow access to the manual switch for maintenance procedures.
The feed pump will not operate properly at ambient temperatures
over 120oF (48oC).
The MPC Control Box
Feed Pump

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The Clark Pump/membrane module comes complete with a mounting system. Be sure to use the
supplied washers on the rubber feet. Use it as a template for drilling the mount holes. Mount in
any position but leave access to the pressure relief valve on the Clark Pump. The membrane
maximum temperature specification is 120oF. This module must be installed in an area that
maintains a temperature below 120oF (50oC). A cool location is preferable. Keep this unit
within the 15’ (4.5 M) reach of the wires from main feed pump module. This unit may be
placed as high in the boat as you desire. Make sure that the area around and under the pump
does not have any water sensitive equipment. Water will be spilled during any repairs or if a
leak occurs. In order to avoid air bubbles getting trapped on the salinity probe electrodes, the
diversion valve/probe assembly must be mounted in a vertical position so that the cable plugs in
at the bottom and the electrodes point up.
The Clark pump and membrane assembly has been pre-assembled at the factory. If it is nec-
essary to disassemble this module and mount the pressure vessel remotely use guidelines in
back of the manual. Use only approved tubing for assembly.
Clark Pump/Membrane Module
Membrane Pressure Vessel Mounting

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Plumbing
From the inlet thru-hull to the flush module and from the flush module to the pump module
inlet, use supplied clear 3/4” (19 mm) spiral suction rated hose. The outlet of the filter assembly
on the main module to the Clark Pump assembly is under pressure. Use the supplied braided
clear vinyl hose rated to 150 PSI (11 bar). From the Clark Pump brine discharge connector, use
supplied 5/8” (15.9 mm) clear braided vinyl hose.
The remote control panel can be mounted anywhere that
is dry and convenient. Cut a 4 9/16” (116 mm) wide by
2 7/8” (68 mm) high opening for the panel. Locate in an
area that is easily visible and easy to manipulate the but-
tons. Use only Spectra approved remote cable.
The cable is not standard LAN cable or phone cord.
Remote Control Panel
NOTE: Route all hoses and tubes to prevent kinks and restrictions. Secure piping away
from moving objects such as engine belts and hatches. Prevent chafe on tubing as re-
quired. Test and inspect all piping and hose clamps after several hours of operation.

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The system from the pump module to the Clark Pump
assembly is under pressure. Use the supplied braided
clear vinyl hose rated to 150 PSI (11 bar).
From the inlet thru-hull to the flush mod-
ule and from the flush module to the
pump module inlet use the supplied clear
3/4(19mm) spiral suction rated hose.
From the Clark Pump brine
discharge connector use the
supplied 5/8(15.9 mm)
clear braided vinyl hose to
the brine overboard fitting.
System Piping Specification
PUMP MODULE
FLUSH MODULE
PREFILTER MODULE
SEA STRAINER
CLARK PUMP/MEMBRANE MODULE
Accumulator, Factory
pre-charged. Install so
that gauge is visible.

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Fresh Water Flush
Run a feed line from the domestic cold pressure water system to the 1/2” hose barb on the fresh
water flush assembly. The boat’s fresh water system must be turned on for the fresh water flush
system to function properly. The domestic fresh water pump must be able to deliver 2.5 gal-
lons per minute at 25 psi. Connect the flush solenoid cable by crimping and heat shrinking the
butt splices. The flush water accumulator is located inside the Feed pump module and should
be precharged to 5psi (0.3bar)
FLUSH WATER INLET

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Product water to
tank
Diversion Valve Solenoid
Brine Discharge
Route the Brine discharge from the
quick disconnect fitting to a location
above the waterline using the
supplied 5/8(15.9 mm) hose.
Quick Disconnect Fitting
Product Water tubing
Product water tubing is 1/4” (6.3 mm) Parker tubing. See the Parker tube fitting assembly
diagram next page. Product water is pre-plumbed from the membrane into the electric diver-
sion valve. The diversion valve will reject product water into the overboard brine stream un-
til good quality is measured by the MPC-5000 control. Product water is then diverted into
the fresh water tank. The salinity probe must be mounted in a vertical position with the ca-
ble coming out the bottom. If the Clark Pump/Membrane Assembly is mounted vertically
or upside down the Diversion Valve/ Probe Assy should be remounted.
You will need to route the product water from the valve into the top of the tank. Install
a tee in the water fill or tap a pipe thread into an inspection port in the top of the tank.
Do not feed the water into a manifold or bottom of the tank. Make sure there is no re-
striction in this plumbing.
RotoFlow Meter
Salinity Probe

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Install the Nut first then use the bevelled side of the Spacer to push the
Grab Ring onto the tube no more than 1/2". Slip the O-ring over the tube
to hold the Spacer in place. If the Grab Ring is pushed too far, trim back
the tube so about 1/4" of tube extends past the O-ring.
Use 2 grab rings for 1/2" tube
Single grab ring for 1/4" & 3/8" tube
1/2" tube should not bottom out in the fitting
to allow full compression of the O-ring
Hand tighten the nut. DO NOT OVER TIGHTEN!
DO NOT USE A WRENCH! The tube should not
come out if pulled by hand. If it does, tighten the
1/4", 3/8", 1/2" Parker Tube Fitting Assembly
Gently fit the tube into the body and loosely thread on the nut.
Be careful not to cross-thread the nut
grab ring tabs.
Step 4:
Step 3:
Step 1: Dissemble fitting components
O-ring
Step 2:
Body
Spacer
Tubing
1/2" max
Nut
Parker Tube Fitting Assembly Procedure

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Membrane Pressure Vessel Relocation
Use ONLY Dayco Imperial Nylo-Seal 88-NSR-1/2tubing for high pressure connections. Pay
attention to the direction and flow path of the tubing before disassembly. Make sure that you
reinstall the tubing in the same manner. Rotate the 90 degree high pressure tube fittings on the
Clark Pump for ideal tube runs. The high pressure fittings are typically pre-installed at the fac-
tory. These fittings seal with an O-ring and require no Teflon tape or pipe dope. Loosen the
backing nut rotate the fitting and reseat the backing nut.
Follow the high pressure tube connection instructions on the next page. Connect the tubes to
one of the components, secure the tube runs, and then trim and connect to the other component.
A 90 degree bend in a tube is better than a 90 degree fitting. A tube, when mounted, should
have at least one gentle bend to allow for expansion. Do not connect a tube straight between
hard mounted fittings.
When connecting the tubes to their components, be sure to hold the fitting body with a wrench
during the final tightening. Of special note are the stainless steel tube fittings on the membrane
housing which seal with an O-ring and should be seated all the way in. Hold the fitting with a
wrench while installing the tube.
The fittings on the Clark pump have an O-ring seal and can be re-oriented by backing out the
O-ring Stop nut. Rotate the fitting to align with the tube and tighten the nut just past hand
tight. DO NOT over tighten!

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Spectra High Pressure Tube Fitting Assembly
Use ONLY Dayco Imperial Nylo-Seal 88-NSR-1/2 tubing for high pressure connections.
Carefully fit and measure the tubing before cutting with a sharp razor knife or hose cutter and remove
any burrs. Minimum tubing bend radius is 6”. Route tubing away from excessive heat sources and
secure from vibration and chafe. Have at least one shallow bend in a tube assembly after it is installed.
Refer to figure 1. If a fitting has been dissembled, reassemble as illustrated. The notch on the ferrule
must engage the inside of the nut properly for the nut to seat down fully. Once the tube is inserted the
ferrule and nut will naturally align.
Refer to figure 2. Insert tube fully into the fitting; it should go in 0.9”. Tighten the nut finger-tight while
moving the tube around to prevent binding. One thread should be showing under the nut. Secure the tube
so it won’t back out when tightening.
Refer to figure 3. Use 13/16” wrench to hold a straight body fitting or a 3/4” wrench for a 90º body, and a
7/8” wrench for the nut. Hold the body, recheck the tube insertion, then tighten the nut 11/4turns. Use the
index mark on the nut as a guide. The threads should be completely covered by the nut.
Make sure these fittings are tight on initial assembly or they will fail!
The correct torque is specification is 85 foot pounds
Tighten 1-2/3 turns (10 flats of the
nut) with a7/8" wrench after finger tight.
Use index mark as guide
Ferrule
Figure 2.
Insert tube 0.9" until it stops
Figure 3.
Figure 1.
Black high pressure tubing
Cut tube square
Nut
Index mark
IMPORTANT!
Hold fitting body with 13/16"
wrench when tightening
No threads showing
Nut finger tight with
1 thread showing
Body
Straight or 90 deg.
3/8" pipe thread
Straight thread

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Wiring
Identify the cables that are connected to the MPC-5000 Control System.
Catalina Magdrive systems have a power inlet harness with a terminal block, fresh water
flush cable, pressure sensor cable harness, and Clark Pump module harness consisting of the
RotoFlow cable, salinity cable and the diversion valve solenoid leads. A 50’(15 M) cable
with connectors is supplied for the MPC-5000 control display.
Power inlet harness
with terminal block
Fresh water flush Cable
50’ (15M) cable with
connectors for the MPC-
5000 control display
Salinity probe cable
Diversion valve
control cable
Connector for
Rotoflow sensor
Clark pump module
harness includes:
Filter module harness
with pressure sensor
plugs
Manual/Auto Switch

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Wiring (continued)
Mount the main power terminals on a bulkhead adjacent to the feed pump module. Make
sure that this is a dry location well above bilge level and not subject to water spray.
Route the control cable through the boat to the MPC display location. Be careful not to dam-
age the connector. Plug this into the back of the control.
Route the Clark Pump harness to the Clark Pump/membrane module location and plug in the
RotoFlow meter. See photo page 15. Plug in the salinity sensor cable and install the plastic
boot over the connection. Locate the diversion valve wires and splice the remaining two
conductor cables with the supplied butt splices The diversion valve wires have no polarity.
Heat-shrink connectors or heat shrink tubing is supplied so you can seal the connections af-
ter splicing.
Route the single two conductor cable to the fresh water flush module and splice the wires to
the solenoid wires. There is no polarity to the wires. Heat the splice for sealing.
Check the wire size chart to select the proper size power feed to the main power harness.
DC power feeds should be uninterruptible to insure proper operation of the auto store fea-
ture. Avoid house breaker panels that could be easily tripped.
Component Sizing:
•12V- Use a 25Amp breaker and size the wiring for 20 Amperes.
•24V– Use a 15 Amp breaker and size the wiring for 10 Amperes.
•Provide circuit protection at the source! Inadequate wiring will cause a loss of
system performance. DC power should be uninterruptible.
Note: If the specified circuit breaker sizes are unavailable, use the next higher rating
but do not exceed the specification by more then 10%. All wiring to be done to
applicable ABYC, Marine UL or CE standards.